Modular chassis

ABSTRACT

A modular chassis is provided for an off-road vehicle to improve assembly, servicing, and repairing of a drivetrain of the off-road vehicle. The modular chassis includes a chassis to support components of the off-road vehicle. A front frame module couples with a front of the chassis, and a rear frame module couples with a rear of the chassis. The front frame module supports lower suspension arms of the off-road vehicle by way of inboard bushing joints. The front frame module supports at least a steering gear and a front differential of the off-road vehicle. The rear frame module is a tube-frame structure that supports components of the off-road vehicle. A lower portion of the rear frame module extends rearward and acutely upward to a top frame member that couples with upper side portions of the chassis. Several cross-members impart structural integrity to the rear frame module.

PRIORITY

This application is a continuation of, and claims the benefit of, U.S.patent application, entitled “Modular Chassis,” filed on Mar. 25, 2019,and having application Ser. No. 16/363,593, which is a continuation of,and claims the benefit of, U.S. patent application, entitled “ModularChassis,” filed on Jun. 16, 2017, and having application Ser. No.15/625,765 which claims the benefit of, and priority to, U.S.Provisional Application, entitled “Off-Road Front Suspension System,”filed on Apr. 3, 2017 and having application Ser. No. 62/480,960, theentirety of each of said applications being incorporated herein byreference.

FIELD

The field of the present disclosure generally relates to vehiclesuspension systems. More particularly, the field of the inventionrelates to a modular chassis for a vehicle configured to improveassembly, servicing, and repairing of a drivetrain of the vehicle.

BACKGROUND

A double wishbone suspension is a well-known independent suspensiondesign using upper and lower wishbone-shaped arms to operably couple afront wheel of a vehicle. Typically, the upper and lower wishbones orsuspension arms each has two mounting points to a chassis of the vehicleand one mounting joint at a spindle assembly or knuckle. A shockabsorber and a coil spring may be mounted onto the wishbone to controlvertical movement of the front wheel. The double wishbone suspensionfacilitates control of wheel motion throughout suspension travel,including controlling such parameters as camber angle, caster angle, toepattern, roll center height, scrub radius, scrub, and the like.

Double wishbone suspensions may be used in a wide variety of vehicles,including heavy-duty vehicles, as well as many off-road vehicles, asshown in FIG. 1. FIG. 1 shows an off-road vehicle 100 that is of a Sideby Side variety. The Side by Side is a four-wheel drive off-road vehiclethat typically seats between two and six occupants, and is sometimesreferred to as a Utility Task Vehicle (UTV), a Recreational Off-HighwayVehicle (ROV), or a Multipurpose Off-Highway Utility Vehicle (MOHUV). Inaddition to the side-by-side seating arrangement, many UTVs have seatbelts and roll-over protection, and some may have a cargo box at therear of the vehicle. A majority of UTVs come factory equipped with hardtops, windshields, and cab enclosures.

Although FIG. 1 shows an off-road vehicle, it should be borne in mindthat double-wishbone suspensions may be incorporated into racingvehicles that are not necessarily intended for off-road racing. Forexample, a double-wishbone suspension may be incorporated into racingvehicles that may be used for any of formula racing, sports car racing,stock car racing, drag racing, touring car racing, production carracing, as well as amateur open-wheel racing applications, such askarting, and the like.

The double-wishbone suspension often is referred to as “double A-arms,”although the arms may be A-shaped, L-shaped, J-shaped, or even a singlebar linkage. In some embodiments, the upper arm may be shorter than thelower arm so as to induce negative camber as the suspension jounces(rises). Preferably, during turning of the vehicle, body roll impartspositive camber gain to the lightly loaded inside wheel, while theheavily loaded outer wheel gains negative camber.

The spindle assembly, or knuckle, is coupled between the outboard endsof the upper and lower suspension arms. In some designs, the knucklecontains a kingpin that facilitates horizontal radial movement of thewheel, and rubber or trunnion bushings for vertical hinged movement ofthe wheel. In some relatively newer designs, a ball joint may bedisposed at each outboard end to allow for vertical and radial movementof the wheel. A bearing hub, or a spindle to which wheel bearings may bemounted, may be coupled with the center of the knuckle.

Constant velocity (CV) joints allow pivoting of the suspension arms andthe spindle assembly, while a drive shaft coupled to the CV jointdelivers power to the wheels. Although CV joints are typically used infront wheel drive vehicles, off-road vehicles such as four-wheeledbuggies comprise CV joints at all wheels. Constant velocity jointstypically are protected by a rubber boot and filled with molybdenumdisulfide grease.

Given that off-road vehicles routinely travel over very rough terrain,such as mountainous regions, there is a desire to improve the mechanicalstrength and performance of off-road drivetrain and suspension systems,while at the same reducing the mechanical complexity of such systems.

SUMMARY

A modular chassis is provided for an off-road vehicle and configured toimprove assembly, servicing, and repairing of a drivetrain of theoff-road vehicle. The modular chassis is comprised of a chassisconfigured to support components of the off-road vehicle, a front framemodule configured to be coupled with a front of the chassis, and a rearframe module configured to be coupled with a rear of the chassis. Thefront frame module is configured to support a first and a second lowersuspension arms of the off-road vehicle by way of inboard mountingjoints of a bushing. A front mount and a rear mount disposed at oppositeends of the front frame module are configured to be fastened onto thechassis. The front frame module is further configured to support variouscomponents of the off-road vehicle, including at least a steering gearand a front differential. One or more service ports disposed on thefront frame module facilitate servicing or repairing of the variouscomponents without requiring removal from the front frame module.

The rear frame module is comprised of a tube-frame structure andconfigured to support various components of the off-road vehicle. Alower portion of the rear frame module is comprised of parallellydisposed, or angled, bottom frame members that extend rearward withrespect to the chassis. Each bottom frame member extends a bent portionthat joins with an angled frame member that extends upwards along alower rear portion of the off-road vehicle. The angled frame memberseach extend to a bent portion that joins with a vertical frame memberthat extends acutely toward a top frame member. The top frame membercomprises a rear-most portion of the rear frame module and is configuredto be coupled with upper side portions of the chassis by way of a topmount disposed at each end of the top frame member. The rear framemodule is centrally disposed with respect to a midline of the chassisand configured to provide clearance for vertical motion of rear trailingarms disposed adjacently to each of the bottom frame members. Severalcross-members are disposed between the bottom frame members, the angledframe members, and the vertical frame members to impart structuralintegrity to the rear frame module.

In an exemplary embodiment, a modular chassis for an off-road vehiclecomprises a chassis configured to support components of the off-roadvehicle; a front frame module configured to be coupled with a front ofthe chassis; and a rear frame module configured to be couple with a rearof the chassis.

In another exemplary embodiment, the front frame module is configured tosupport a first lower suspension arm on a passenger side and a secondlower suspension arm on a driver side of the off-road vehicle by way ofinboard mounting joints of a bushing variety that allow the first lowersuspension arm and the second lower suspension arm to pivot verticallywith respect to the front frame module. In another exemplary embodiment,the front frame module is an elongate member comprised of inboardmounting brackets disposed on opposite sides in locations suitable toreceive the first lower suspension arm and the second lower suspensionarm.

In another exemplary embodiment, the front frame module is comprised ofa front mount and a rear mount disposed at opposite ends and configuredto enable fastening the front frame module to the chassis. In anotherexemplary embodiment, the front mount is comprised of a bracketconfigured to be coupled with a similar bracket disposed at a front-mostportion of the chassis. In another exemplary embodiment, the rear mountis configured to be coupled with a tube-shaped member comprising thechassis, a bracket suitable for receiving the rear mount being fastenedor welded onto the tube-shaped member of the chassis.

In another exemplary embodiment, the front frame module is configured tosupport various components of the off-road vehicle, the variouscomponents being comprised of at least a steering gear and a frontdifferential. In another exemplary embodiment, one or more service portsare disposed on the front frame module to facilitate servicing orrepairing of the various components without requiring removal from thefront frame module, at least one of the one or more service portsproviding access to an oil drain plug of a front differential. Inanother exemplary embodiment, at least one of the one or more serviceports are disposed on the front frame module to allow fluids to drainfrom an interior of the front frame module. In another exemplaryembodiment, the front frame module is comprised of one or more panelsconfigured to protect various components coupled with the front framemodule, the one or more panels being comprised of at least one debrisshield to protect a steering gear and a front differential from damagedue to flying road debris.

In another exemplary embodiment, the rear frame module is comprised of atube-frame structure and configured to support various components of theoff-road vehicle. In another exemplary embodiment, a frame componentmount may be fastened to the chassis and located within the rear framemodule so as to support various components of the off-road vehicle. Inanother exemplary embodiment, one or more holes are disposed in variouslocations of the frame component mount so as to receive the variouscomponents that are intended to be supported by the frame componentmount.

In another exemplary embodiment, a lower portion of the rear framemodule is comprised of parallelly disposed, or angled, bottom framemembers that extend rearward with respect to the chassis, each toward abent portion that joins each of the bottom frame members with an angledframe member that extends upwards along a lower rear portion of theoff-road vehicle to a bent portion that joins each of the angle framemembers with a vertical frame member that extends acutely toward a topframe member. In another exemplary embodiment, a bottom mount comprisesthe fear frame module and is configured to couple the bottom framemembers with the chassis. In another exemplary embodiment, the bottommount is comprised of brackets that are configured to receive suitablysized nuts and bolts that fasten the bottom frame members to thechassis, a cross-member being disposed between the bottom frame membersand receivable between the brackets so as to fixedly join the bottomframe members with the chassis. In another exemplary embodiment, thebottom frame members are centrally disposed adjacent to a midline of thechassis and configured to provide clearance for vertical motion of arear trailing arm disposed adjacently to each of the bottom framemembers. In another exemplary embodiment, several cross-members aredisposed between the bottom frame members, the angled frame members, andthe vertical frame members and configured to impart structural integrityto the rear frame module. In another exemplary embodiment, the top framemember comprises a rear-most portion of the rear frame module and isconfigured to be coupled with upper side portions of the chassis by wayof a top mount disposed at each end of the top frame member, the topmount being comprised of a suitable means for fixating the top framemember and the upper side portions.

In an exemplary embodiment, a modular chassis for a vehicle, comprises:a chassis for supporting components of the vehicle; a front frame modulefor coupling with a front of the chassis; and a rear frame module forcoupling with a rear of the chassis.

In another exemplary embodiment, the front frame module supports a firstlower suspension arm on a passenger side and a second lower suspensionarm on a driver side of the vehicle by way of inboard mounting jointsthat allow the first lower suspension arm and the second lowersuspension arm to pivot vertically with respect to the front framemodule. In another exemplary embodiment, the front frame module is anelongate member comprised of inboard mounting brackets disposed onopposite sides in locations suitable to receive the first lowersuspension arm and the second lower suspension arm.

In another exemplary embodiment, the front frame module includes a frontmount and a rear mount disposed at opposite ends. In another exemplaryembodiment, the front mount includes a bracket for coupling with asimilar bracket disposed at a front-most portion of the chassis. Inanother exemplary embodiment, the rear mount is configured to be coupledwith a bracket that is fastened or welded onto the chassis.

In another exemplary embodiment, the front frame module is configured tosupport at least a steering gear and a front differential of thevehicle. In another exemplary embodiment, the front frame moduleincludes one or more service ports to provide access to variouscomponents supported by the front frame module. In another exemplaryembodiment, at least one of the one or more service ports providesaccess to an oil drain plug of a front differential. In anotherexemplary embodiment, at least one of the one or more service ports areconfigured to allow fluids to drain from an interior of the front framemodule.

In another exemplary embodiment, the front frame module includes one ormore panels for protecting various components coupled with the frontframe module. In another exemplary embodiment, the one or more panelsincludes at least one debris shield to protect a steering gear and afront differential from damage due to road debris. In another exemplaryembodiment, the rear frame module comprises a tube-frame structure thatis configured to support various components of the vehicle. In anotherexemplary embodiment, the rear frame module includes one or more framecomponent mounts to support various components of the vehicle. Inanother exemplary embodiment, one or more holes are disposed in each ofthe one or more frame component mounts and configured to receive thevarious components of the vehicle.

In another exemplary embodiment, a lower portion of the rear framemodule comprises parallel bottom frame members that extend rearward andupward toward a top frame member. In another exemplary embodiment, eachbottom frame member joins with an angled frame member that extendsupwards to a bent portion that joins the angled frame member with avertical frame member that extends acutely toward the top frame member.In another exemplary embodiment, one or more cross-members are disposedbetween any of the bottom frame members, the angled frame members, andthe vertical frame members to impart structural integrity to the rearframe module. In another exemplary embodiment, the top frame membercomprises a rear-most portion of the rear frame module and is configuredto be coupled with upper side portions of the chassis by way of a topmount disposed at each end of the top frame member. In another exemplaryembodiment, the top mount comprises a suitable means for coupling thetop frame member with the upper side portions.

In another exemplary embodiment, the rear frame module includes a bottommount for coupling the bottom frame members with the chassis. In anotherexemplary embodiment, the bottom mount comprises brackets for fasteningthe bottom frame members to the chassis. In another exemplaryembodiment, a cross-member is disposed between the bottom frame membersand configured to be fastened between the brackets. In another exemplaryembodiment, each bottom frame member is adjacent to a midline of thechassis and provides clearance for vertical motion of a rear trailingarm coupled with the chassis.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings refer to embodiments of the present disclosure in which:

FIG. 1 illustrates an exemplary embodiment of an off-road vehicle thatis particularly suitable for implementation of an off-road frontsuspension system in accordance with the present disclosure;

FIG. 2 illustrates a front view of a front suspension system that isconfigured to couple a front wheel with a passenger side of an off-roadvehicle;

FIG. 3A illustrates an upper isometric view of an exemplary embodimentof a front frame module that is fixedly coupled with a modular chassisof an off-road vehicle;

FIG. 3B illustrates a bottom plan view of the front frame module of FIG.3A;

FIG. 3C illustrates an isometric view of an exemplary embodiment of afront frame module coupled with a modular chassis of an off-road vehicleand supporting a steering gear and a front differential;

FIG. 4A illustrates a bottom plan view of an exemplary embodiment of afront frame module that may be fixedly coupled with a modular chassis ofan off-road vehicle;

FIG. 4B illustrates a top plan view of the front frame moduleillustrated in FIG. 4A;

FIG. 4C illustrates a side plan view of the front frame module of FIG.4A;

FIG. 5A illustrates an isometric view of an exemplary embodiment of arear frame module that is fixedly coupled with a modular chassis of anoff-road vehicle;

FIG. 5B illustrates a rear plan view of the rear frame module coupledwith the modular chassis of the off-road vehicle as illustrated in FIG.5A;

FIG. 6A illustrates a side plan view of the rear frame module coupledwith the modular chassis of the off-road vehicle as illustrated in FIG.5A; and

FIG. 6B illustrates a top plan view of the rear frame module coupledwith the modular chassis of the off-road vehicle as illustrated in FIG.5A.

While the present disclosure is subject to various modifications andalternative forms, specific embodiments thereof have been shown by wayof example in the drawings and will herein be described in detail. Theinvention should be understood to not be limited to the particular formsdisclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth inorder to provide a thorough understanding of the present disclosure. Itwill be apparent, however, to one of ordinary skill in the art that theinvention disclosed herein may be practiced without these specificdetails. In other instances, specific numeric references such as “firstjoint,” may be made. However, the specific numeric reference should notbe interpreted as a literal sequential order but rather interpreted thatthe “first joint” is different than a “second joint.” Thus, the specificdetails set forth are merely exemplary. The specific details may bevaried from and still be contemplated to be within the spirit and scopeof the present disclosure. The term “coupled” is defined as meaningconnected either directly to the component or indirectly to thecomponent through another component. Further, as used herein, the terms“about,” “approximately,” or “substantially” for any numerical values orranges indicate a suitable dimensional tolerance that allows the part orcollection of components to function for its intended purpose asdescribed herein.

In general, the present disclosure describes a modular chassis for anoff-road vehicle that is configured to improve assembly, servicing, andrepairing of a drivetrain of the off-road vehicle. The modular chassisis comprised of a chassis configured to support components of theoff-road vehicle. A front frame module is configured to be coupled witha front of the chassis, and a rear frame module is configured to becoupled with a rear of the chassis. The front frame module supportslower suspension arms of the off-road vehicle by way of inboard bushingjoints that allow the lower suspension arms to pivot vertically withrespect to the front frame module. The front frame module is configuredto support various components of the off-road vehicle, including atleast a steering gear and a front differential. One or more serviceports facilitate servicing or repairing of the various componentswithout requiring removal from the front frame module.

The rear frame module is comprised of a tube-frame structure that isconfigured to support various components of the off-road vehicle. Alower portion of the rear frame module is comprised ofdirectionally-parallel bottom frame members that each extends rearwardto a bent portion that joins with an angled frame member. The angledframe members each extend to a bent portion that joins with a verticalframe member that extends acutely toward a top frame member. The topframe member comprises a rear-most portion of the rear frame module thatis configured to be coupled with upper side portions of the chassis.Several cross-members are disposed between the bottom frame members, theangled frame members, and the vertical frame members to impartstructural integrity to the rear frame module. The rear frame module isconfigured to provide clearance for vertical motion of rear trailingarms disposed adjacently to each of the bottom frame members.

FIG. 1 shows an off-road vehicle 100 that is particularly suitable forimplementation of a modular chassis system in accordance with thepresent disclosure. As disclosed hereinabove, the off-road vehicle 100generally is of a Utility Task Vehicle (UTV) variety that seats twooccupants, includes a roll-over protection system 104, and may have acab enclosure 108. Rear wheels 112 of the off-road vehicle 100 may beoperably coupled with a chassis 116 by way of a trailing arm suspensionsystem. Front wheels 120 may be operably coupled with the chassis 116 byway of the front suspension system.

In addition to the off-road applications discussed herein, it iscontemplated that, in some embodiments, the modular chassis may beincorporated into racing vehicles that are not necessarily intended foroff-road racing. For example, the modular chassis may be incorporatedinto vehicle that includes a tube-frame structure as well as racingvehicles that include any of formula racing, sports car racing, stockcar racing, drag racing, touring car racing, production car racing, aswell as amateur open-wheel racing applications, such as karting, and thelike. In such applications, the modular chassis advantageously enables adrivetrain and suspension assembly to be quickly and easily assembled,serviced, and repaired, unlike in the case of conventional racingvehicles that may be sidelined during a race due to the failure of anindividual part that requires a time consuming procedure to access andreplace. As such, the vehicle 100 illustrated in FIG. 1 should beconstrued as including any vehicle that is suitable for the modularchassis disclosed herein, without limitation.

FIG. 2 illustrates a front view of a front suspension system 124 that isconfigured to couple the front wheel 120 with a passenger side of thevehicle 100. The front suspension system 124 is comprised of an uppersuspension arm 128 and a lower suspension arm 132 that couple the frontwheel 120 with the chassis 116. Each of the upper and lower suspensionarms 128, 132 comprises two inboard mounting joints 136 to the chassis116 and one outboard mounting joint to a spindle assembly 140. As willbe recognized, the upper and lower suspension arms 128, 132 generallyare of a double wishbone variety of suspension that facilitatescontrolling various parameters affecting the orientation of the wheel120 with respect to the vehicle 100, such as, by way of non-limitingexample, camber angle, caster angle, toe pattern, roll center height,scrub radius, and scrub.

It should be understood that although the front suspension system 124 isdisclosed specifically in connection with the passenger side of thevehicle 100, a driver side front suspension system is to be coupled witha driver side of the vehicle. It should be further understood that thedriver side front suspension system is substantially identical to thefront suspension system 124, with the exception that the driver sidefront suspension system is configured specifically to operate with thedriver side of the vehicle 100. As will be appreciated, therefore, thedriver side front suspension system and the front suspension system 124may be configured as reflections of one another across a longitudinalmidline of the vehicle 100.

As will be appreciated by those skilled in the art, there may beinstances wherein disassembling one or more portions of the chassis 116may be advantageous, such as during servicing or repairing of componentscomprising the front suspension system 124. Further, assembling one ormore portions of the chassis 116 simples manufacturing of the vehicle100, as well as facilitating repairing damaged portions of the chassis116 without cutting and welding the chassis as is commonplace withconventional vehicles. To this end, the illustrated embodiment of thechassis 116 may be comprised of one or more portions, or chassismodules, that may be assembled and disassembled, as needed.

FIGS. 3A-3C illustrate an exemplary embodiment of a front frame module144 that may be fixedly coupled with the chassis 116. The front framemodule 144 generally supports the lower suspension arms 132 on thepassenger and driver sides of the vehicle 100 by way of the inboardmounting joints 136. The inboard mounting joints 136 preferably are of abushing variety that allow the lower suspension arms 132 to pivotvertically with respect to the front frame module 144. As best shown inFIGS. 4A-4C, the front frame module 144 is generally an elongate membercomprised of inboard mounting brackets 148 disposed on opposite sides ofthe front frame module in locations suitable to receive the lowersuspension arms as shown in FIGS. 3A-3B. As will be appreciated, thefront frame module 144 is comprised of a rigid metal, such as any ofvarious suitable metal alloys, having a gauge thickness suitable forsupporting the vehicle 100 and withstanding the forces due to the lowersuspension arms 132 due to travel over terrain.

The front frame module 144 is comprised of a front mount 152 and a rearmount 156 disposed at opposite ends and configured to enable fasteningthe front frame module to the chassis 116. In the illustratedembodiment, the front mount 152 is comprised of a bracket configured tobe coupled, such as by way of nuts and bolts, with a similar bracketdisposed at a front-most portion of the chassis 116. The rear mount 156is configured to be coupled with a tube-shaped member comprising thechassis 116. In some embodiments, a bracket suitable for receiving therear mount 156 may be fastened or welded onto the tube-shaped member ofthe chassis 116. It should be understood, however, that the front andrear mounts 152, 156 are not to be limited to the specificconfigurations shown and discussed herein, but rather the front and rearmounts 152, 156 may be comprised of any structure suitable for fixedlycoupling the front frame module 144 with the chassis 116.

As best shown in FIG. 3C, the front frame module 144 may be configuredto support various components of the vehicle 100. For example, in theillustrated embodiment, a steering gear 160 and a front differential 164may be fastened onto the front frame module 144. As shown in FIGS.4A-4C, the front frame module 144 includes a steering mount 168configured to receive the steering gear 160, and comprises a pluralityof brackets 172 suitable for receiving fasteners to mount the frontdifferential 164 onto the front frame module. It is contemplated thatsuitably sized nuts and bolts may be utilized to fasten the steeringgear 160 onto the steering mount 168. Similarly, suitably sized boltsmay be used to fasten the front differential 164 onto the plurality ofbrackets 172. Further, in some embodiments, the brackets 172 may beconfigured to receive any of various cushioning mounts, such as rubbermounts, that may be coupled between the front differential 164 and thefront frame module 144.

In some embodiments, the front frame module 144 may include variousports, or openings, disposed on the front frame module to provide accessto the various components fastened onto to the front frame module. Inthe embodiment illustrated in FIGS. 4A-4C, the front frame module 144includes service ports 176. As will be appreciated, the service portsgenerally facilitate servicing or repairing of the various componentswithout requiring removal from the front frame module 144. Those skilledin the art will recognize that the service ports 176 facilitateaccessing an oil drain plug of the front differential 164 for thepurpose of draining and refilling the front differential gear oil. Itshould be understood, however, that the front frame module 144 is notlimited to the service ports 176 illustrated herein, and thus otheropenings and service ports may be incorporated into the front framemodule 144, as deemed necessary, without limitation. For example, any ofvarious service ports 176 may be disposed on the front frame module 144so as to allow fluids, such as trapped water due to travel in wetconditions, to drain from an interior of the front frame module, therebyinhibiting potential corrosion of the front frame module 144.

As shown in FIGS. 3A-3C, the front frame module 144 may be comprised ofone or more panels that are configured to protect the various componentscoupled with the front frame module. For example, the illustratedembodiment of the front frame module 144 is comprised of debris shields180 that serve to protect the steering gear 160 and the frontdifferential 164 from damage due to flying road debris, such as rocks,that may occur during travel over rough terrain.

FIGS. 5A-5B illustrate an exemplary embodiment of a rear frame module184 that may be fixedly coupled with the chassis 116. The rear framemodule 184 generally is comprised of a tube-frame structure that isconfigured couple with the chassis 116 and to support various enginecomponents, as well as a transaxle and rear differential (not shown).The rear frame module 184 may be comprised of any suitably rigid metal,or non-ferrous materials, such as any of various metal alloys, having agauge thickness suitable for supporting the vehicle 100 and withstandingforces typically encountered during travel over rough terrain.

As best shown in FIG. 5A, a lower portion of the rear frame module 184is comprised of parallelly disposed bottom frame members 188 that extendrearward with respect to the chassis 116, each toward a bent portion192. A bottom mount 186 is configured to couple the bottom frame members188 with the chassis 116. The bottom mount 186 may be comprised ofbrackets that are configured to receive suitably sized nuts and boltsthat fasten the bottom frame members 188 to the chassis 116. In someembodiments, a cross-member may be disposed between the bottom framemembers 188 and received between the brackets so as to fixedly join thebottom frame members 188 with the chassis 116. It is contemplated thatthe bottom mount 186 may be comprised of any suitable means for fixatingthe rear frame module 184 to the chassis 116, without limitation.

In the embodiment illustrated in FIG. 5A, the bottom frame members 188are centrally disposed adjacent to a midline of the chassis 116 andconfigured to provide clearance for vertical motion of driver side andpassenger side rear trailing arms (not shown) disposed adjacently toeach of the bottom frame members 188. The bent portions 192 join each ofthe bottom frame members 188 with an angled frame member 196 thatextends upwards along a lower rear portion of the vehicle 100. A bentportion 200 joins each of the angle frame members 196 with a verticalframe member 204 that extends acutely toward a top frame member 208.Several cross-members 202 are disposed between the parallel bottom framemembers 188, angled frame members 196, and vertical frame members 204.As will be appreciated, the cross-members 202 serve to fixate theparallel frame members, 188, 196, 200, and thereby impart structuralintegrity to the rear frame module 184.

As best shown in FIGS. 6A-6B, the top frame member 208 comprises arear-most portion of the rear frame module 184 that may be coupled withupper side portions 212 of the chassis 116. The illustrated embodimentof the top frame member 208 is comprised of a series of straight tubeportions and bent tube portions that are suitably assembled such thatthe top frame member 208 may be joined with the upper side portions 212by way of a top mount 216 disposed at each end of the top frame member.The straight tube portions and the bent tube portions may be separatetube portions that are assembly to form the top frame member 208, or thestraight tube portions and the bent tube portions may comprise a singletube portion that is advantageously manipulated to form the top framemember 208. Further, it is contemplated that the top mounts 216 may becomprised of any suitable means for fixating the top frame member 208and the upper side portions 212. In some embodiments, for example, thetop mounts 216 may be comprised of suitably sized couplers that areinserted between the top frame member 208 and the upper side portions212 and then welded to fixate the rear frame module 184 and the chassis116. Other means for fixating the top frame member 208 and the upperside portions 212 will be apparent to those skilled in the art.

It is contemplated that a wide variety of brackets and other supportivemembers may be coupled with the rear frame module 184 and the chassis116 so as to support various components of the vehicle 100, such asengine components, as well as a transaxle and rear differential (notshown). For example, in the illustrated embodiment of FIGS. 5A-6B, aframe component mount 220 may be fastened to the chassis 116 so as to beadvantageously located within the rear frame module 184 to support theabovementioned components. As best shown in FIG. 6B, the frame componentmount 220 may be fastened to the chassis 116 by way of brackets 224configured to receive suitably sized bolts and nuts. It is contemplatedthat the brackets 224 may be welded onto the chassis 116, such that oneor more holes in the brackets 224 may be aligned with mounting holes inthe frame component mount 220.

Moreover, it is further contemplated that any of various brackets,holes, or openings may be coupled with, or disposed on, the framecomponent mount 220 for the purpose of fixedly receiving variouscomponents of the vehicle, as described herein. For example, as bestshown in FIG. 6A, two component mounting brackets 228 are coupled withthe frame component mount 220. The component mounting brackets 228 maybe welded, or otherwise fastened onto the frame component mount 220,without limitation, in a parallel orientation to facilitate supporting arelatively heavy component of the vehicle 100. Further, as shown in FIG.5A, holes 232 are disposed in various locations of the frame componentmount 220. It is contemplated that the holes 232 may be strategicallylocated so as to receive various components that are intended to befastened onto the frame component mount 220.

It should be understood that neither the rear frame module 184 nor thefront frame module 144 are to be limited to the specific shapes andstructures shown in the illustrations and disclosed herein. Inparticular, the various brackets, holes, openings, and couplersdisclosed herein are intended to be exemplary in nature, and thus any ofthe disclosed brackets, holes, openings, and couplers may be modified,varied, or exchanged for an equivalent, without limitation and withoutdeviating beyond the spirit and scope of the present disclosure.

Moreover, it should be understood that the modular chassis disclosedherein is not limited solely to the chassis 116, the front frame module144, and the rear frame module 184, but rather it is contemplated thatthe chassis 116 may be further comprised of one or more modules, asdesired. For example, in some embodiments, the chassis 116 may becomprised of the abovementioned roll-over protection system 104implemented as a single component, or an assembly of components, thatmay be fastened onto the chassis 116, and removed therefrom as needed.It is further contemplated that the one or more modules comprising thechassis 116 may include any of various brackets, mounts, holes,openings, couplers, and the like, that may be deemed necessary toassemble the modules comprising the chassis 116 and to couple vehiclecomponents with the chassis, without limitation.

Furthermore, it should be borne in mind that the modular chassisdisclosed herein may be incorporated into racing vehicles that are notnecessarily intended for off-road racing. For example, the modularchassis may be incorporated into racing vehicles that may be used forany of formula racing, sports car racing, stock car racing, drag racing,touring car racing, production car racing, as well as amateur open-wheelracing applications, such as karting, and the like. It is contemplatedthat in such applications, the modular chassis advantageously enables adrivetrain and suspension assembly to be quickly and easily assembled,serviced, and repaired, unlike in the case of conventional racingvehicles that may be sidelined during a race due to the failure of anindividual part that requires a time consuming procedure to access andreplace. As such, the vehicle 100 illustrated in FIG. 1 should beconstrued as including any vehicle that is suitable for implementationof the modular chassis as disclosed herein, without limitation, andwithout deviating beyond the spirit and scope of the present disclosure.

While the invention has been described in terms of particular variationsand illustrative figures, those of ordinary skill in the art willrecognize that the invention is not limited to the variations or figuresdescribed. In addition, where methods and steps described above indicatecertain events occurring in certain order, those of ordinary skill inthe art will recognize that the ordering of certain steps may bemodified and that such modifications are in accordance with thevariations of the invention. Additionally, certain of the steps may beperformed concurrently in a parallel process when possible, as well asperformed sequentially as described above. To the extent there arevariations of the invention, which are within the spirit of thedisclosure or equivalent to the inventions found in the claims, it isthe intent that this patent will cover those variations as well.Therefore, the present disclosure is to be understood as not limited bythe specific embodiments described herein, but only by scope of theappended claims.

What is claimed is:
 1. A modular chassis for a vehicle, comprising: achassis for supporting components of the vehicle; a front frame modulefor coupling with a front of the chassis; and a rear frame module forcoupling with a rear of the chassis.
 2. The modular chassis of claim 1,wherein the front frame module supports a first lower suspension arm ona passenger side and a second lower suspension arm on a driver side ofthe vehicle by way of inboard mounting joints that allow the first lowersuspension arm and the second lower suspension arm to pivot verticallywith respect to the front frame module.
 3. The modular chassis of claim2, wherein the front frame module is an elongate member comprised ofinboard mounting brackets disposed on opposite sides in locationssuitable to receive the first lower suspension arm and the second lowersuspension arm.
 4. The modular chassis of claim 1, wherein the frontframe module includes a front mount and a rear mount disposed atopposite ends.
 5. The modular chassis of claim 4, wherein the frontmount includes a bracket for coupling with a similar bracket disposed ata front-most portion of the chassis.
 6. The modular chassis of claim 5,wherein the rear mount is configured to be coupled with a bracket thatis fastened or welded onto the chassis.
 7. The modular chassis of claim1, wherein the front frame module is configured to support at least asteering gear and a front differential of the vehicle.
 8. The modularchassis of claim 1, wherein the front frame module includes one or moreservice ports to provide access to various components supported by thefront frame module.
 9. The modular chassis of claim 1, wherein the frontframe module includes one or more panels for protecting variouscomponents coupled with the front frame module.
 10. The modular chassisof claim 1, wherein the rear frame module comprises a tube-framestructure that is configured to support various components of thevehicle.
 11. The modular chassis of claim 1, wherein the rear framemodule includes one or more frame component mounts to support variouscomponents of the vehicle.
 12. The modular chassis of claim 1, wherein alower portion of the rear frame module comprises parallel bottom framemembers that extend rearward and upward toward a top frame member. 13.The modular chassis of claim 12, wherein each bottom frame member joinswith an angled frame member that extends upwards to a bent portion thatjoins the angled frame member with a vertical frame member that extendsacutely toward the top frame member.
 14. The modular chassis of claim13, wherein one or more cross-members are disposed between any of thebottom frame members, the angled frame members, and the vertical framemembers to impart structural integrity to the rear frame module.
 15. Themodular chassis of claim 13, wherein the top frame member comprises arear-most portion of the rear frame module and is configured to becoupled with upper side portions of the chassis by way of a top mountdisposed at each end of the top frame member.
 16. The modular chassis ofclaim 15, wherein the top mount comprises a suitable means for couplingthe top frame member with the upper side portions.
 17. The modularchassis of claim 12, wherein the rear frame module includes a bottommount for coupling the bottom frame members with the chassis.
 18. Themodular chassis of claim 17, wherein the bottom mount comprises bracketsfor fastening the bottom frame members to the chassis.
 19. The modularchassis of claim 18, wherein a cross-member is disposed between thebottom frame members and configured to be fastened between the brackets.20. The modular chassis of claim 12, wherein each bottom frame member isadjacent to a midline of the chassis and provides clearance for verticalmotion of a rear trailing arm coupled with the chassis.